Method for decorating surfaces

ABSTRACT

A glitter coating composition is applied from a manuallyoperated aerosol spray can by spraying a glitter coating composition comprising solid, highly reflectant, non-leafing polymer-coated metal flakes, a vehicle system therefor, and a propellant by the steps of (1) flowing the glitter coating composition through a passageway of substantially uniform crosssectional area, (2) expanding the flowing glitter composition in an elongated expansion chamber, and (3) accelerating the expanded flowing glitter composition through a constricted orifice. The glitter coating issues from the orifice in the form of a finelydivided well-mixed spray.

United States Patent 1191 Coffey et a1. Oct. 9, 1973 METHOD FORDECORATING SURFACES 3,402,066 9/1968 Caffras 117/104 A [751 CharlesCoffey; Michael 3:333:82? 25131; 533;; f??..?.:.::::: IZZY/1 7 41 0 1Catena, both of Tampa, Fla. 73] H P t 6 T Fl OTHER PUBLICATIONS sslgnce'arms am ompany ampa Herzka, International Encyclopaedia of Pressurized[22] Filed: Jan. 26, 1972 Packaging (1966) Pergamon Press Press, pages532,

545 & 546. [21] Appl' 221033 Felsher et al., Paint & Varnish Production,May 1963,

Related US. Application Data pgs. 42-45. [63] Continuation-impart ofSer. No. 44,590, June 8,

1970, abandoned. Primary ExaminerWil1iam D. Martin Assistant Examiner-M.Sofocleus [52] US. Cl 239/1, 106/193 M, 117/27, Attorney-Edwin E. Greigg222/402.1, 260/37 M [57] ABSTRACT [51] Int. Cl B44d 1/08, 865d 83/14 Aglitter Coating composition is applied from a manu [58] Field of Search117/37 R, 93.4, 27, any operated aerosol spray can by spraying a glitter7/104 104 160 33; coating composition comprising solid, highly reflect-252/305; 260/37 M; 106/193 M; 222/394 ant, non-leafing polymer-coatedmetal flakes, a vehi- 4021; 424/46 cle system therefor, and a propellantby the steps of (1) flowing the glitter coating composition through a[56] References C'ted passageway of substantially uniformcross-sectional UNITED STATES PATENTS area, (2) expanding the flowingglitter composition in 2,731,436 1/1956 Stetz et a1. 252/305 anelongated expansion chamber, and (3) accelerating 2,934,512 4/1960Godshalk 117/160 X the expanded flowing glitter composition through a3,1 11,497 11/1963 Haas l17/160 X constricted orifice. The glittercoating issues from the 3,121,642 BlSkUp rifi e in the form of awel].mixed 3,234,038 2/1966 Stephens et a1... 117/71 M Spray 2,908,44610/1959 Strouse 222/4021 9/1964 Marsh 167/87.1 16 Claims, No DrawingsMETHOD FOR DECORATING SURFACES This application is acontinuation-in-part of application Ser. No. 44,590, filed June 8, 1970,entitled Method for Decorating Surfaces and now abandoned.

SUMMARY OF THE INVENTION This invention relates to a method fordepositing solid, highly reflectant, non-leafing, sparkling, colored,macro," polymer-coated metal flakes on any primed or unprimed substrate,e.g., styrofoam, metal, wood, plastic, paper, which can support a film.

Colored metal flakes in the macro size range have heretofore beenlimited to application from conventional, heavy-duty spray equipment, orhave had to be roller coated, screen printed, cast, flocked, orextruded.

It is an object of this invention to apply, solid, highly reflectant,non-leaflng colored, macro" size metal flakes from a manually-operatedaerosol spray can. By the practice of this invention, students, artists,home handymen, housewives, auto enthusiasts, and the like can applydramatic glitter coatings to numerous substrates and can obtainesthetically pleasing effects previously unavailable except by usingheavy-duty spray equipment.

Prior to this invention, it was known in the art to apply micro" leafingmetal particles from manuallyoperated spray cans. The formulations usedby Felsher et al (Paint and Varnish Products, May 1963, at p. 45), byHerzka (International Encyclopedia of Pressurized Packaging." PergamonPress. I966. at pgs. 545,546), and by Stetz et al (U. S. Pat. No.2,731,436) create a mirror-like surface by the use ofleafing" metalflakes, usually in the size range of 200-325 mesh (00029-00017inch)..Coatings made by aerosol application of these formulations feelsmooth, show a decided tendency to crock, and become dull after a shorttime. Stephens ct al(U. S. Pat. No. 3,234,038) teach the use of l-200mesh (0.0058-00029 inch) nonleafing aluminum flakes in a formulationapplied from conventional heavy-duty spray equipment to a primed surfaceand then baked. A transparent lacquer overcoat is required. Thecompositions do not adhere satisfactorily to unprimed surfaces and arerelatively dull grey in appearance.

Coatings made according to the present invention appear sparkling andglittery and feel rough to the touch. Good adhesion to unprimedsurfaces, e.g., metal, wood, plastic, paper, is obtained by the simpleprocess of spraying the glitter coating composition from amanually-operated aerosol can. No overcoat is required, since theglitter coatings show virtually no tendency to peel, crack, or rub off.

The effect produced by the solid, highly reflectant, non-leafing,polymer-coated metal flakes of this invention is thought to reside inpropelling the flakes onto a substrate in a random, unoriented fashion.Rapid evaporation of volatile solvent from the vehicle results in theflakes being embedded randomly in the resin from the vehicle system.Each flake is thought to be coated with a thin layer of resin. Part ofthe brilliance and sparkle of the coatings of this invention is thoughtto be due to reflectance of light through the coating on each metalflake.

The size of the macro metal flakes used in the practice of thisinvention may be varied according to the effect desired. Use of a largersize flake gives a more dramatic appearance to the substrate sprayedthan use of smaller flakes. The size of the metal flake may vary fromabout 0.004 inch X 0.002 inchX 0.00032 inch to about 0.008 inch X 0.008inch X 0.00] inch. Flakes in the range from 0.004 inch X 0.002 inch X0.00045 inch to 0.008 inch X 0.008 inch X 0.00045 inch are preferred.Tolerances are within i 5 percent in both surface dimensions andthickness.

Metal flakes particularly preferred for the purpose of this inventionare precision-cut, regular shapes of highly polished aluminum foilcoated with a variety of coatings, depending on the type of coloredflake desired. The epoxy coated type are aluminum foil flakes coatedwith a pigmented, or unpigmented, baked epoxy resin. The vinyl coatedtype are aluminum foil flakes coated with a pigmented, or unpigmented,vinyl resin. The nitrocellulose coated type are aluminum foil flakescoated with a pigmented, or unpigmented, nitrocellulose type lacquer.

Colors of the flakes include the following, or mixtures thereof:

Bright Silver Purple Sand Prussian Blue Pale GOlCl Royal Blue Dark GOldMedium Blue Golden Fiesta Aqua Chartreuse Emerald Golden Orange LavenderBright Orange Brilliant Copper Apricot Antique Brown Brilliant Red BlackFuchsia Vehicle systems which have successfully been used in this methodinclude conventional acrylic resins, e.g., F-lO [a poly(methylmethacrylate) (Rohm and Haas Co.)]; alkyd resins, e.g., vinyltoluenesoya alkyd; methyl cellulose; and the like. The polymer used in thevehicle system may be any polymer which is not reactive with the coatingon the metal flakes. The vehicle composition is limited only by thestrength of the solvents used. Solvents used in the aerosol formulationsshould be of low solvent strength. However, this does not preclude theuse of minor percentages of strong solvents. Very strong solvents are tobe avoided, as they could possibly solubilize and extract colorants fromthe coated aluminum flakes.

Propellants used include both halogenated types and hydrocarbon types'ofconventional aerosol propellants.

In the examples infra there will be shown a basel consisting of themetal flakes and vehicle therefor. This base is delivered to an openaerosol can, suitable agitators are added (spherical marbles or rivetsare adequate); the spray valve is crimped onto the aerosol can, and thepropellant is injected into the can. While low temperature filling ispossible, the injection method is more suited to the practice of thisinvention.

Conventional, cylindrical aerosol cans of any size can be used for thepractice of this invention; 4 ounce to 16 ounce cans are preferred.

The velocity at which the glitter coating composition is exhausted fromthe spray can is a critical aspect of successful application ofcompositions containing macro flakes from a spray container.Conventional sprayheads apparently confine the mixing and atomization ofspray compositions to a localized region adjacent to the nozzle outlet.An unsatisfactory spray pattern often results, particularly with liquidproducts containing dispersed solid particles or flakes, e.g., specialtypaints containing flakes of metallic, plastic, or glass glitter. Theparticles in these products apparently serve as'nuclei for agglomerationof liquid in relatively large droplets which collect in the area betweenthe sprayhead and the valve mounting cap. As exhaustion of the aerosolfrom the can is continued, the bulk of collected fluid is carried byentrainment as a blotch, spatter, or unsightly non-uniform area on thesubstrate being sprayed. These poor results become even more poor as thesize of the suspended flakes or particles increases.

A sprayhe ad suitable for propulsion ofmacro particles of this inventionrequires the incorporation of an elongated expansion chamber upstream ofthe nozzle orifice. The diameter of the expansion chamber should ideallybe significantly larger than that of the passageway leading'to the valvefrom a dip tube or other means for conveying glitter coating compositionto the passageway of the sprayhead.

The length of the expansion chamber should preferably be several timesits diameter. For example, a sprayhead incorporating an expansionchamber at least five times as long as its diameter not only gives aspray pattern of greatly improved uniformity, but also gives increasedproduct flow rate for a given nozzle orifice diameter and propellantpressure.

Thus, in the operation of this invention, the glitter coatingcomposition and propellant mixture undergoes the steps of l flow througha passageway of substantially uniform cross'sectional area, (2)expansion within an elongated expansion chamber, and (3) accelerationthrough a constricted orifice. The glitter coating issues from theorifice in the form of a finelydivided well-mixed spray.

In a particularly useful sprayhead, the expansion chamber is placedangularly with respect to the passageway of the sprayhead. Glittercoating composition first passes through the passageway of substantiallyuniform cross-sectional area. The abrupt change of direction which thecomposition undergoes as it enters the expansion chamber induces aswirling flow which promotes intimate mixing of flakes, vehicle, andvaporizing propellant as the composition passes through the expansionchamber prior to issuing from the constricted orifice as a very finespray.

Dimensions of a typical sprayhead which gives results useful for thepurpose of this invention are:

Inlet slot 0.060 inch X 0.125 inch Chamber 0.112 inch diameter X 0.625inch long Orifice 0.032 inch diameter While the invention is not limitedto specific sprayhead slots and orifices, the following sprayheads,manufactured by Newman-Green, Inc., have been found to be suitable:

Valves useful in the practice of this invention include B and R typevalves manufactured by Newman-Green, Inc. of Addison, Illinois. Valvesdenoted R-10-l28 and B-l4-l0-l28 are especially useful, although othervalves of these series are operative.

When larger sized metal flakes are used, the use of a vapor tap valveassembly is preferred, as this assembly substantially eliminates thepossibility of the valve dip tube becoming clogged with metal flakes.The vapor tap feature is available on both B and R type valves, supra.

To further ensure elimination of clogging the valve dip tube with macroflakes, the dip tube should terminate slightly above the level normallyoccupied by a compacted sludge of metal flakes of the coatingcomposition which forms between successive usages of the aerosol spraycan. Negligible loss of material results from this arrangement of thedip tube.

Before spraying the product of this invention, the coating compositionis agitated thoroughly by shaking the aerosol can. The spherical marblesor rivets charged to the can operate as agitating means. Labeldirections on the can should indicate the need for frequent shaking toassure that equal aliquots of macro" flakes and vehicle are dischargedthroughout the use of a given spray can.

In the practice of the invention, aerosol formulations are charged intothe aerosol can, the sprayhead is affixed, the aerosol can is shaken toensure distribution of the contents, the sprayhead is pressed, and thevalve assembly is actuated to deliver the product onto the desiredsubstrata.

The following are examples of formulations that may be used:

EXAMPLE 1 Base 2.0 g F-l0 Rohm and Haas Acrylic Solution 4.0 g Pale GoldEpoxy 0.008 inch X 0.006 inch 0.00045 inch Flake 39.0 g Textile SpiritsAmsco Propellant 55.0 g Freon l2/Vinyl Chloride Blend 65%/35% Du PontEXAMPLE 2 Base 2.5 g F-l0 3.0 g Pale Gold Epoxy 0.008 inch X 0.006 inchx 0.00045 inch 67.5 g Cyclohexane Am. Min. Sp. Propellant 30.0 g A-Hydrocarbon Propellant Aeropres, Inc.

EXAMPLE 3 Base 20.0 g F-l0 2.0 g Pale Gold Epoxy 0.008 inch X 0.008 inch0.00045 inch 50.0 g Process Naphtha Humble Oil 0.1 g DC-200 Silicone DowCorning 0.9 g Toluol Propellant 30.0 g A-70 Hydrocarbon PropellantExample 4 Base 25.0 g F-lO 25.0 g Process Naphtha 2.0 g Pale Gold Epoxy0.008 inch 0.004 inch X 0.00045 inch Propellant 50.0 g Freon l2/VinylChloride 65%/35% EXAMPLE 5 Base 30.0 g F-lO 20.0 g Process Naphtha 0.1 gDC-200 Silicone 0.9 g Toluol 2.0 g Pale 001d Epoxy 0.008 inch x 0.008inch 0.00045 inch Propellant 50.0 g Freon 12/Vinyl Chloride 65%/35%EXAMPLE 6 Base 5.0 g Pale Gold Epoxy 0.008 inch X 0.008 inch X 0.00045inches 0.5 g Malori Maroon Tint Paste 15.0 g Vinyl Toluene Soya AlkydSolution 60% N 4 30.0-g Process Naphtha Propellant 50.0 g Freon l2/VinylChloride 65%/35% EXAMPLE 7 Base 5.0 g Pale Gold Epoxy 0.008 inch X 0.008inch X 0.00045 inch 0.25 g Phthalo Green Tint Paste 15.0 g Vinyl TolueneSoya Alkyd Solution 60% V 25.0 g Process Naphtha Propellant 55.0 g Freon65%/35% l2/Vinyl Chloride EXAMPLE 8 Base 4.0 g Pale Gold Epoxy 0.008inch X 0.008 inch X 0.00045 inch 20.0 g Vinyl Toluene Soya AlkydSolution 60% V 36.0 g Process Naphtha 10.0 g lsopropyl AlcoholPropellant- 30.0 g A-70 Propellant EXAMPLE 9 EXAMPLE 10 Base 25.0 g F-lO25.0 g Process Naphtha 2.0 g Silver Vinyl Coated Flake 0.008 inch X0.004 inch X 0.001 inch Propellant 50.0 g A-70 Hydrocarbon PropellantEXAMPLE 11 Base 4.0 g Medium Blue Nitrocellulose Coated Aluminum Flakes41.0 g Water 5.0 g 3% Methocel CPS 4000 in water 30.0 g lsopropylAlcohol 0.4 g Emcol 14 Propellant 20.0 g A-70 Hydrocarbon Propellant Itwill be apparent from the foregoing examples that color can be impartedto the vehicle by inclusion therein of a dye or transparent pigment. Bythe use of transparent colored and colorless vehicles and by the use ofmetal flakes coated with unpigmented and pigmented resins, a myriadvariety of glitter effects can be obtained.

That which is claimed is:

l. A method for applying a glitter coating composition from a manuallyoperated aerosol can which comprises spraying the glitter compositioncomprising from about 0.5 percent to about 10 percent of solid, highlyreflectant, non-leafing aluminum flakes, the size of which variesbetween about 0.002 inch X 0.004 inch X 0.00032 inch and about 0.008inch X 0.008 inch X 0.001 inch coated with a polymer selected from thegroup consisting of baked epoxy resin, vinyl resin and nitrocelluloseresin, from about 40 percent to about 83 percent of a vehicle system forthe aluminum flakes, and from about 15 percent to about 55 percent of anaerosol propellant by the steps of flowing said glitter compositionthrough a passageway of substantially uniform cross-sectional area,flowing said glitter into an elongated expansion chamber of which thelength is several times its diameter, and arranged angularly withrespect to the passageway, expanding said flowing glitter composition inthe elongated expansion chamber, and accelerating said expanded flowingglitter composition through a constricted orifice in the form of afinely divided well mixed spray.

2. The method of claim 1, wherein the vehicle system contains dyes ortransparent pigments.

3. The method of claim 1, wherein the aluminum flakes are. coated with apigmented polymer.

4. The method of claim 1, wherein the aluminum flakes are precision-cut,regularly shaped flakes of aluminum foil.

5. The method of claim 1, wherein the aluminum flakes are precision-cut,regularly shaped flakes of aluminum foil coated with a pigmentedpolymer.

6. The method of claim 1, wherein the aluminum flakes are precision-cut,regularly shaped flakes of aluminum foil and wherein the vehicle systemcontains dyes or transparent pigments.

7. The method of claim 11, wherein the aluminum flakes areprecision-cut, regularly shaped flakes of aluminum foil, coated with apigmented polymer and wherein the vehicle system contains dyes ortransparent pigments. I

8. The method of claim 1, wherein the manually operated aerosol canincludes a vapor-tap valve assembly.

9.. The method of claim 1, wherein the manually operated aerosol canincludes a vapor-tap valve assembly and further wherein means forflowing said glitter coating composition into the passageway ofsubstantially uniform cross-sectional area terminates slightly above alevel normally occupied by a compacted sludge of aluminum flakes of saidglitter coating composition which forms between successive usages ofsaid'aerosol can.

10. The method of claim 1, wherein a swirling motion is imparted to saidflowing glitter composition entering the elongated expansion chamber byabruptly changing the direction of flow of said flowing glittercomposition as said composition enters said expansion chamber.

11. The method of claim 10, wherein the vehicle system contains dyes ortransparent pigments.

flakes are precision-cut, regularly shaped flakes of aluminum foil andwherein the vehicle system contains dyes or transparent pigments.

16. The method of claim 10, wherein the aluminum flakes areprecision-cut, regularly shaped flakes of aluminum foil coated with apigmented polymer and wherein the vehicle system contains dyes ortransparent pigments.

2. The method of claim 1, wherein the vehicle system contains dyes ortransparent pigments.
 3. The method of claim 1, wherein the aluminumflakes are coated with a pigmented polymer.
 4. The method of claim 1,wherein the aluminum flakes are precision-cut, regularly shaped flakesof aluminum foil.
 5. The method of claim 1, wherein the aluminum flakesare precision-cut, regularly shaped flakes of aluminum foil coated witha pigmented polymer.
 6. The method of claim 1, wherein the aluminumflakes are precision-cut, regularly shaped flakes of aluminum foil andwherein the vehicle system contains dyes or transparent pigments.
 7. Themethod of claim 1, wherein the aluminum flakes are precision-cut,regularly shaped flakes of aluminum foil, coated with a pigmentedpolymer and wherein the vehicle system contains dyEs or transparentpigments.
 8. The method of claim 1, wherein the manually operatedaerosol can includes a vapor-tap valve assembly.
 9. The method of claim1, wherein the manually operated aerosol can includes a vapor-tap valveassembly and further wherein means for flowing said glitter coatingcomposition into the passageway of substantially uniform cross-sectionalarea terminates slightly above a level normally occupied by a compactedsludge of aluminum flakes of said glitter coating composition whichforms between successive usages of said aerosol can.
 10. The method ofclaim 1, wherein a swirling motion is imparted to said flowing glittercomposition entering the elongated expansion chamber by abruptlychanging the direction of flow of said flowing glitter composition assaid composition enters said expansion chamber.
 11. The method of claim10, wherein the vehicle system contains dyes or transparent pigments.12. The method of claim 10, wherein the aluminum flakes are coated witha pigmented polymer.
 13. The method of claim 10, wherein the aluminumflakes are precision-cut, regularly shaped flakes of aluminum foil. 14.The method of claim 10, wherein the aluminum flakes are precision-cut,regularly shaped flakes of aluminum foil, coated with a pigmentedpolymer.
 15. The method of claim 10, wherein the aluminum flakes areprecision-cut, regularly shaped flakes of aluminum foil and wherein thevehicle system contains dyes or transparent pigments.
 16. The method ofclaim 10, wherein the aluminum flakes are precision-cut, regularlyshaped flakes of aluminum foil coated with a pigmented polymer andwherein the vehicle system contains dyes or transparent pigments.